Modular buildings and methods of construction thereof

ABSTRACT

A method of assembling a modular building includes affixing a plurality of horizontally-extending metal bands to a shear core. The metal bands are spaced vertically from one another along a vertical axis defined by the shear core. Modular units are coupled to the shear core via the metal bands.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of and priority to U.S. Provisional Application No. 62/539,658, filed on Aug. 1, 2017, the entire contents of which are incorporated by reference herein.

BACKGROUND Technical Field

The present disclosure relates generally to modular buildings. More particularly, the present disclosure relates to shear cores of modular buildings and methods of connecting modular units to shear cores.

Background of Related Art

Modular units are commonly used for constructing commercial, residential, medical, and industrial structures because they can be partially assembled/constructed remote from the building site and transported to the building site for assembly into a complete building structure. One method of constructing modular buildings utilizes a concrete shear core that functions as a primary structural element for the building. A concrete shear core is generally a large, hollow, vertical column of reinforced concrete, located generally at an interior of the building. The concrete shear core provides a sturdy central structural member that, cooperatively with peripheral columns and transverse beams, reacts to the static and dynamic loads imposed by and on the building. The concrete shear core often houses many of the building services, such as the elevators, utilities, and the like. Modular units may be stacked on top of one another and bolted to a periphery of the concrete shear core.

One drawback to the above-identified construction method is that the stacked modular units may be too close or too far from the shear core to be connected. In addition, there is often a limited amount of available surface area on the shear core to which a modular unit can be attached.

Accordingly, a need exists for an improved method of connecting modular units to shear cores in modular buildings.

SUMMARY

In one aspect of the present disclosure, a method of assembling a modular building is provided. The method includes affixing a plurality of horizontally-extending metal bands to a shear core, and coupling a modular unit to a first metal band of the plurality of metal bands. The metal bands are spaced vertically from one another along a vertical axis defined by the shear core.

Some methods may further include welding a metal plate to an outer surface of the first metal band, and welding the metal plate to an upper surface of the modular unit, thereby coupling the modular unit to the shear core. The metal plate may extend horizontally along a mateline defined by the first metal band.

In some methods, coupling the modular unit to the first metal band may include welding the modular unit to the first metal band.

In some methods, the metal bands may be fabricated from steel.

In some methods, the metal bands may be exposed from an outer surface of the shear core.

In some methods, the first metal band may be affixed to the shear core via at least one anchor extending inwardly from an inner surface of the first metal band. The anchor may be embedded within the shear core.

In some methods, the anchor may be connected to a reinforcing bar embedded within the shear core.

In some methods, the shear core may be fabricated from concrete.

In some methods, the metal bands may be plates that extend across a majority of the width of an outer surface of the shear core.

In another aspect of the present disclosure, a vertically-extending structure for supporting modular units is provided. The structure includes a concrete shear core having an outer surface, and a plurality of horizontally-extending metal bands fixed to the outer surface of the concrete shear core. The metal bands are spaced vertically from one another along a vertical axis defined by the concrete shear core.

In some embodiments, the structure may further include a metal plate welded to an outer surface of a first metal band of the plurality of metal bands.

In some embodiments, the metal plate may be further welded to an upper surface of a modular unit, such that the modular unit is coupled to the concrete shear core via the metal plate.

In some embodiments, the metal plate may extend horizontally along a mateline defined by the first metal band.

In some embodiments, the metal bands may be fabricated from steel.

In some embodiments, the metal bands may be exposed from the outer surface of the concrete shear core.

In some embodiments, each of the metal bands may include at least one anchor extending inwardly from an inner surface thereof. The anchor may be embedded within the concrete shear core.

In some embodiments, the anchor may be connected to a reinforcing bar embedded within the concrete shear core.

In some embodiments, the metal bands may be plates that extend across a majority of the width of the outer surface of the concrete shear core.

In some embodiments, the metal bands may be spaced vertically from one another a distance substantially equal to a height of a modular unit.

Further details, advantages, and aspects of exemplary embodiments of the present disclosure are described in more detail below with reference to the appended figures.

As used herein, the term “about” or “approximately” applies to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure.

As used herein, the term “coupled” means either a direct mechanical connection between the components that are connected, or an indirect mechanical connection through one or more intermediary components.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:

FIG. 1 is a perspective view of an embodiment of structures of a modular building in accordance with the principles of the present disclosure;

FIG. 2 is a perspective view of the modular building of FIG. 1 having a plurality of modular units affixed thereto;

FIG. 3 is a side, perspective view of a ceiling assembly of a modular unit coupled to an outer surface of a shear core of the modular building of FIG. 1, with a connector plate shown disassembled from the shear core and the modular unit; and

FIG. 4 is a cross-section, taken along line 4-4 of FIG. 3, illustrating the modular unit coupled to the shear core with the connector plate shown assembled to the shear core and the modular unit.

DETAILED DESCRIPTION

Embodiments of the presently disclosed modular buildings and methods of construction are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views.

The present disclosure provides an improved method of connecting modular units to a shear core of a modular building. The shear core has a plurality of elongate plates extending horizontally across a face of the shear core. The elongate plates are fixed to the shear core by anchors embedded within the concrete or steel of the shear core. The elongate plates provide a large surface area on which the modular units can be coupled (e.g., via welding). In embodiments, each modular unit may be either directly welded to a respective elongate plate, or coupled to a respective elongate plate via a discrete steel plate that is welded to both an upper surface of the modular unit and an outer surface of the respective elongate plate. These and other features of the modular building and its construction will be described in further detail herein.

Referring initially to FIGS. 1 and 2, illustrated is a vertically-extending structure (hereinafter “modular building) generally designated by reference numeral 10. The modular building 10 includes a shear core 12 supported on a podium or platform 14, and a plurality of modular units or modules 16. The shear core 12 is a vertically-extending tower supported on the podium 14 and is fabricated from concrete reinforced with rods, beams, and/or a wire grid. The shear core 12 is the primary structural element to which the modular units 16 are coupled. The shear core 12 may assume any suitable shape, such as, for example, box-like, planar, cylindrical, or the like. The shear core 12 defines a height “h” and a width “w” and has a planar outer surface or face 18 for attachment of the modular units 16.

With reference to FIGS. 1-4, the modular building 10 includes a plurality of horizontally-extending, elongated metal bands 20 fixed to the outer surface 18 of the shear core 12. The metal bands 20 and may have a plate-like configuration and be fabricated from steel. The metal bands 20 extend horizontally from a first side surface 12 a of the shear core 12, across the entire width “w” of the shear core 12, to a second side surface 12 b of the shear core 12. In embodiments, the metal bands 20 may only extend partially across the width “w” of the shear core 12. Each of the metal bands 20 is spaced vertically from one another along a vertical axis “y” defined by the shear core 12. The distance between adjacent metal bands 20 may be substantially equal to a height of the modular unit 16 selected for use in the modular building 10.

With specific reference to FIGS. 3 and 4, the metal bands 20 have a planar, outer surface 20 a, and a planar, inner surface 20 b. The outer surface 20 a of each of the metal bands 20 is exposed from the outer surface 18 of the shear core 12 to allow for on-site welding of the modular units 16 thereto. It is contemplated that the outer surface 20 a of each of the metal bands 20 may be coplanar with the outer surface 18 of the shear core 12 (while remaining exposed). In other embodiments, the outer surface 20 a of each of the metal bands 20 may protrude outwardly from the outer surface 18 of the shear core 12.

The metal bands 20 include anchors 22 (e.g., tiebacks, bolts, or any other suitable connector) extending perpendicularly from the inner surface 20 b of the metal bands 20. The anchors 22 of each metal band 20 may be disposed in a pair of linear rows extending horizontally along the inner surface 20 b of the metal band 20. A first of the pair of linear rows of anchors 22 may be disposed adjacent a first longitudinally-extending upper edge 24 a of the metal band 20, whereas a second of the pair of linear rows of anchors 22 may be disposed adjacent a longitudinally-extending lower edge 24 b of the metal band 20. The anchors 22 of each metal band 20 may have a first end 26 connected to or monolithically formed with the inner surface 20 b of the metal band 20, and a second end 28 configured to be embedded in the concrete of the shear core 12. In embodiments, the second end 28 of each of the anchors 22 may be connected to reinforced bars 30 (e.g., rebar) extending within the concrete of the shear core 12, such that the metal bands 20 are immobile relative to the shear core 12.

The modular building 10 may further include a plurality of steel plates 32 for interconnecting the modular units 16 and the metal bands 20. The steel plates 32 are planar, rectangular, and dimensioned to occupy an exposed corner section 34 of an upper surface 36 of a modular unit 16. In embodiments, the steel plate 32 may be fabricated from any suitable metal and may be any suitable dimension. The steel plate 32 has a first lateral edge 32 a and a second lateral edge 32 b. The first lateral edge 32 a is configured to be connected (e.g., via welding) to the metal band 20 at a horizontally-extending midline or mateline “M” defined by the metal band 20. The second lateral edge 32 b is configured to be connected (e.g., via welding) to the corner section 34 of the upper surface 36 of the modular unit 16.

Each of the modular units 16 includes horizontal structural steel members 40, vertical structural steel members 42, and a cement board 44 supported on the upper surface 36 of the modular unit 16. The cement board 44 covers a majority of the upper surface 36 of the modular unit 16, but leaves exposed the corner section 34 to allow for welding at this location. Each of the modular units 16 may be prefabricated at an off-site facility, and then delivered to the intended site of use. The modular units 16 are set onto the podium 14 (FIG. 1) and joined together to make a single building 10. The modular units 16 may be placed side-by-side, end-to-end, or stacked on top of one another during construction.

A method of constructing the modular building 10 will now be described. To construct the modular building 10, the shear core 12 is formed on-site during which the metal bands 20 are affixed to the outer surface 18 of the shear core 12. The modular units 16 may be secured to the shear core 12 by first attaching a first horizontal row of modular units 16 to the metal band 20 located lowest on the shear core 12 and subsequently attaching a second horizontal row of modular units 16 to the metal band 20 located immediately above the lowest metal band 20. To secure each modular unit 16 to the shear core 12, the modular unit 16 may be directly connected to the metal band 20 via welding. In some methods, instead of a direct connection, the steel plate 32 may be utilized to couple the modular unit 16 to the shear core 12.

In particular, the steel plate 32 is affixed to the metal band 20 using a continuous, full penetration weld between the outer surface 20 a of the metal band 20 and the first lateral edge 32 a of the steel plate 32. In this way, the steel plate 32 extends perpendicularly outward from the metal band 20 while also extending along the mateline “M.” With the steel plate 32 fixed to the metal band 20, the modular unit 16 is positioned directly below the steel plate 32 and spaced a selected, tolerated distance from the outer surface 18 of the shear core 12. In embodiments, the modular unit 16 may be disposed flush with the outer surface 18 of the shear core 12.

The corner section 34 of the upper surface 36 of the modular unit 16 is positioned in contact with an underside of the steel plate 32. The modular unit 16 is fixed to the steel plate 32 using a continuous, full penetration weld between the corner section 34 of the upper surface 36 of the modular unit 16 and the second lateral edge 32 b of the steel plate 32. Upon welding the modular unit 16 to the steel plate 32, the steel plate 32 functions to interconnect the modular unit 16 and the shear core 12. The remaining modular units 16 of the first horizontal row are likewise secured to the metal band 20. Upon welding each of the modular units 16 of the first horizontal row, a second horizontal row of modular units 16 may be attached to the metal band located immediately above the first row of modular units 16. This process is continued until the modular building 10 has the desired number of rows of modular units 16.

It will be understood that various modifications may be made to the embodiments and methods disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments and methods. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended thereto. 

1. A method of assembling a modular building, the method comprising: affixing a plurality of horizontally-extending metal bands to a shear core, the metal bands being spaced vertically from one another along a vertical axis defined by the shear core; positioning a modular unit adjacent to a first metal band of the plurality of metal bands a selected, tolerated distance from an outer surface of the first metal band; and welding a metal plate to the outer surface of the first metal band and an upper surface of the modular unit, thereby coupling the modular unit to the shear core while being spaced the selected, tolerated distance from the outer surface of the first metal band.
 2. The method according to claim 1, wherein welding the metal plate to the upper surface of the modular unit includes welding an underside of the metal plate to a corner section of the upper surface of the modular unit.
 3. The method according to claim 2, wherein the metal plate extends horizontally along a mateline defined by the first metal band.
 4. (canceled)
 5. The method according to claim 1, wherein the plurality of metal bands are fabricated from steel.
 6. The method according to claim 1, wherein the plurality of metal bands are exposed from an outer surface of the shear core.
 7. The method according to claim 1, wherein the first metal band is affixed to the shear core via at least one anchor extending inwardly from an inner surface of the first metal band, the at least one anchor being embedded within the shear core.
 8. The method according to claim 7, wherein the at least one anchor is connected to a reinforcing bar embedded within the shear core.
 9. The method according to claim 7, wherein the shear core is fabricated from concrete.
 10. The method according to claim 1, wherein the plurality of metal bands are plates that extend across a majority of the width of an outer surface of the shear core.
 11. A vertically-extending structure for supporting modular units, comprising: a concrete shear core having an outer surface; a plurality of horizontally-extending metal bands fixed to the outer surface of the concrete shear core, wherein the plurality of metal bands are spaced vertically from one another along a vertical axis defined by the concrete shear core; a metal plate welded to an outer surface of a first metal band of the plurality of metal bands; and a modular unit having an upper surface welded to an underside of the metal plate, wherein the modular unit is spaced a selected, tolerated distance from the outer surface of the first metal band.
 12. (canceled)
 13. The vertically-extending structure according to claim 11, wherein the metal plate covers a corner section of the upper surface of the modular unit.
 14. The vertically-extending structure according to claim 11, wherein the metal plate extends horizontally along a mateline defined by the first metal band.
 15. The vertically-extending structure according to claim 11, wherein the plurality of metal bands are fabricated from steel.
 16. The vertically-extending structure according to claim 11, wherein the plurality of metal bands are exposed from the outer surface of the concrete shear core.
 17. The vertically-extending structure according to claim 11, wherein each of the plurality of metal bands includes at least one anchor extending inwardly from an inner surface thereof, the at least one anchor being embedded within the concrete shear core.
 18. The vertically-extending structure according to claim 17, wherein the at least one anchor is connected to a reinforcing bar embedded within the concrete shear core.
 19. The vertically-extending structure according to claim 17, wherein the plurality of metal bands are plates that extend across a majority of the width of the outer surface of the concrete shear core.
 20. The vertically-extending structure according to claim 11, wherein the plurality of metal bands are spaced vertically from one another a distance substantially equal to a height of a modular unit. 